Manufacturing Processes I · Metal Forming · 2 marks · Numerical answer
A90 mm cylindrical billet is extruded into the illustrated I-section. Mean flow stress is80 MPa and $p_e=\sigma_m[0.8+1.2\ln(A_0/A_f)]$. Find extrusion force in kN (one decimal).
The two flanges each have area50×5 and the web60×5 mm², so Af=800 mm². Initial area A₀=π90²/4=6361.73 mm². The pressure is80[0.8+1.2ln(6361.73/800)]≈263.04 MPa. Force=pₑA₀≈1.673×10⁶ N=1673 kN.
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